Methods for classifying petroleum coke

ABSTRACT

A method of determining the identity of a petroleum coke sample including obtaining a nuclear magnetic resonance (NMR) measurement of the sample, determining a relaxation decay value of a fluid in the sample from the NMR measurement, comparing the relaxation decay value to relaxation decay values of known petroleum coke materials in a reference group to determine whether the petroleum coke is one of the known materials.

TECHNICAL FIELD

This disclosure relates to the general subject of classification of petroleum coke.

BACKGROUND

Delayed coking is a thermal cracking process used in petroleum refineries to upgrade and convert high-boiling-range hydrocarbon residues into liquid and gas product streams, leaving behind solid carbonaceous material in the process' coke drums.

The solid coke material may have several different types of morphologies, depending upon the specific feedstock and coking conditions. Virgin petroleum residues (bottoms from atmospheric and vacuum distillation of crude oil) can produce cokes which can be classified as “sponge coke” (see for example P. Ellis, C. Paul, “Tutorial: Delayed Coking Fundamentals,” AlChE 1998 Spring Meeting, New Orleans, La., Mar. 8-12, 1998, Paper 29a), “shot coke” (see for example H. Marsh, C. Calvert, J. Bacha, “Structure and Formation of Shot Coke-a Microscopic Study,” J. of Materials Science 20 (1985) 289-302), “transition coke” (see for example M. Siskin, S. Kelemen, C. Eppig, L. Brown, M. Afeworki, “Asphaltene Molecular Structure and Chemical Influences on the Morphology of Coke Produced in Delayed Coking,” Energy & Fuels 20 (2006) 1227-1234) and in some cases “dense coke” (see for example U.S. Pat. No. 9,139,781 “Delayed Coking Process”). In addition, highly aromatic oils such as FCC fractionator bottoms slurry oil will produce in delayed cokers what is known as “needle coke”.

The physical structures and chemical properties of the petroleum coke determine the end use of the coke which can be burned as fuel, calcined for use in the aluminum, chemical, or steel industries, or gasified to produce steam, electricity, or gas feedstocks for the petrochemicals industry.

Commercial sales contracts for sponge coke which is destined to be calcined for use in the aluminum manufacturing industry normally specify key properties such as metals, sulfur, and volatile materials content. Because of adverse effects of shot coke in calcination-grade sponge coke, contracts normally also specify that there be zero shot coke present, or have substantial penalties for presence of any shot coke in the bulk product mixture. In these instances, there is need for quantitative determination of the fraction of shot coke which may be present in sponge coke.

The accuracy of existing testing methods for determining coke morphology can be “questionable”. Attempts to increase testing accuracy have involved using larger samples but this has led to lengthened testing durations.

It is desired to have test methods for determining identity of petroleum coke that are both accurate and do not involve long testing durations.

SUMMARY

One aspect of the instant disclosure relates to a method of using hydrogen NMR measurements of a coke sample to measure the amount of hydrogen present in the sample. This measurement is a measurement of moisture content in the sample. The moisture is usually in the form of water but can be another NMR active fluid present in the pores and/or interstitial regions of the coke sample. Measurements of the moisture content are used to identify the coke sample for classification purposes.

Another aspect of the instant disclosure relates to a method of saturating a coke sample with a NMR active fluid (such as water) and examining the sample using NMR. The internal microstructures of different types of coke show different NMR measurement results. The coke sample is classified based on the NMR results.

Another aspect of the instant disclosure relates to a method wherein a coke sample is saturated with a NMR active fluid and then scanned in a NMR apparatus. The results of the scan are then used to determine the amount of various types of coke present in the sample as a percentage of the total amount of coke in the sample.

Another aspect of the instant disclosure relates to a method for quantitatively and rapidly determining physical morphologies of petroleum coke, including sponge, shot and dense-cokes, by infusing and saturating a representative coke sample with a NMR active fluid such as water, measuring the log mean T₂ log with a low field NMR instrument, and assigning the coke sample a morphology based on the measured log mean T₂. The sample may include more than one type of petroleum coke.

Another aspect of the instant disclosure relates to a method of determining the identity of a petroleum coke sample including obtaining a nuclear magnetic resonance (NMR) measurement of the sample, determining a relaxation decay value of a fluid in the sample from the NMR measurement, comparing the relaxation decay value to relaxation decay values of known petroleum coke materials in a reference group to determine whether the petroleum coke is one of the known materials.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a conventional NMR pulse diagram of a Carr-Purcell-Meilboom-Gill (CPMG) sequence usable in methods of the present disclosure;

FIG. 2 illustrates a conventional NMR pulse diagram of an Inversion Recovery (IR) sequence usable in methods of the present disclosure;

FIG. 3 is a flowchart depicting an example method for classifying coke;

FIG. 4a is a graph illustrating the T₂ relaxation distribution for a first Type A coke sample;

FIG. 4b is a graph illustrating the T₂ relaxation distribution for a second Type A coke sample;

FIG. 4c is a graph illustrating the T₂ relaxation distribution for a first Type C coke sample;

FIG. 4d is a graph illustrating the T₂ relaxation distribution for a second Type C coke sample;

FIG. 4e is a graph illustrating the T₂ relaxation distribution for a first Type D coke sample;

FIG. 4f is a graph illustrating the T₂ relaxation distribution for a second Type D coke sample; and

FIG. 5 is a plot of porosity versus the T₂ log mean of coke samples.

DETAILED DESCRIPTION

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings, and will herein be described hereinafter in detail, some specific embodiments of the instant invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments or algorithms so described.

The present invention in one embodiment relates to a method of using NMR to investigate different internal structures (pore and interstitial regions) of different types of coke. The internal structures of a coke sample are filled with water (or other NMR active fluid) and the relaxation decay of the fluid is measured using NMR. The relaxation decay is directly affected by the internal structure of the coke sample.

The relaxation parameter used can be a T₁ or T₂ relaxation decay. The relaxation parameters T₁ and T₂ can be measured using a conventional NMR measurement pulse sequence. In certain embodiments, parameters of the sequence are selected to measure the range of T₁ or T₂ expected. The raw data is analyzed by fitting a sum of exponential as described by equation (1):

$\begin{matrix} {{S(t)} = {\sum\limits_{i = 1}^{N}{{A(i)}e^{- \frac{t}{T_{2}{(i)}}}}}} & (1) \end{matrix}$

where T₂ ^((i)) is the list of T₂ values that are chosen to be fitted to; t is the time (for example, increments of 2*TAU can be used); A(i) is the amplitude or amount of signal at the T₂ ^((i)) value; i is the current T₂ value to fit to (for example, ˜100 T₂ values log spaced between 0.01 ms and 10 sec can be used); and S(t) is the signal as a function of time.

This equation can be solved by minimizing equation (2):

$\begin{matrix} {{Error}{= {\sqrt{\sum\limits_{t = {TE}}^{t = {j*{TE}}}\left( {{m(t)} - {\sum\limits_{i = 1}^{N}{{A(i)}e^{- \frac{t}{T_{2}{(i)}}}}}} \right)^{2}} + {\alpha \sqrt{\underset{i = 1}{\sum\limits^{N}}{A(i)}^{2}}}}}} & (2) \end{matrix}$

where m(t) is the measured signal as a function of time; J is the echo number and the balance of the variables are as per equation (1).

The alpha or smoothing factor, α, can be determine by a variety of methods (Butler 1981).

In one embodiment, a conventional inversion recovery sequence, such as depicted in FIG. 1, is used to measure the T₁ relaxation decay. The inversion recovery sequence is repeated at different recovery times (TI) and the detected signal recovers with the relaxation constant of T₁. A conventional Carr-Purcell-Meilboom-Gill (CPMG) NMR pulse sequence, such as depicted in FIG. 2, can be used to measure T₂. In FIG. 2, the T₂ relaxation decay parameter is the decay of the acquired echoes (marked with x's) over time.

Examples

Two samples (I and II) of three different types of coke (A, C and D) were tested using the exemplary method 100 illustrated in FIG. 3. In step 1, a coke sample is dried to remove fluid present in the sample. Step 1 is optional. In step 2, the coke sample is saturated with water by placing the sample under vacuum, introducing water to wet pores and interstitial regions of the sample and then releasing the vacuum. The vacuum created inside the sample facilitates the water to enter the pores and interstitial regions of the sample. It will be understood by those skilled in the art that other suitable sample wetting techniques can be used. In step 3, the T₂ relaxation decay of the sample is measured using a conventional NMR apparatus (not shown) programmed to apply a CPMG pulse sequence to samples. In step 4, the T₂ relaxation decay measurement is analyzed to obtain a T₂ relaxation decay parameter value. The T₂ relaxation decay parameter value is compared to known classification parameter values for coke types in a reference group of coke types to determine whether a known coke type is present in the sample tested. At this point, for example, results of the identification can be outputted. Step 4 can be implemented as computer-executable instructions in a computing environment (not shown). This could be as simple as classification based on the average to T₂ value. Or more complicated such as a fit to a mathematical equation using predetermined T₂ distribution of each COKE type. For example, the mathematical equation could be:

ERROR=measured T ₂−(Type A T ₂*weight A+Type B T ₂*weight B+ . . . )

The “ . . . ” in the above equation is included to indicate that this type * weighting can be extended to the various types of coke which are to be classified. The computing environment can be integrated with the NMR apparatus of step 3 or can be separate.

FIG. 4 are graphs illustrating T₂ relaxation distributions for two samples of three different types of coke tested in this example. Differences in the porosity and the average T₂ value were observed for the different types of Coke samples. Table 1 lists the peak T₂ relaxation time, the average T₂ relaxation time (log mean), the maximum T₂ value, the NMR porosity, and the NMR porosity of the dry samples. The peak time is the T₂ time with the maximum intensity. The log mean is the T₂ time that divides the distribution into two equal areas (like an average). The NMR porosity is the total area under the distribution which is the total porosity of the water occupied pores (which at 100% saturation is all of them).

TABLE 1 T₂ Dry NMR T₂ Log T₂ @ NMR Porosity Sample Peak Mean 99% Porosity Contribution Number (ms) (ms) (ms) (p.u.) (p.u) Type A I 2818 2424 5623 15.7 0.062 Type A II 2818 2551 5623 14.9 0.077 Type C I 1000 279 2512 8.3 0.48 Type C II 1258 362 3162 9.6 0.51 Type D I 1995 1184 5012 8.0 0.095 Type D II 1995 1149 5012 6.0 0.14

FIG. 5 is a plot comparison and differentiation of petroleum coke samples based on porosity versus T₂ log mean. Groupings for each coke type identified are shown.

In this example, three different types of coke were found to be present in the samples: Type A which was primarily sponge Coke, Type C which was primarily shot Coke and Type D which was primarily a denser Coke that is not that common.

In one embodiment, coke samples are classified by using a “cut-off” method which uses the T₂ log mean value. A sample is classified based on the range of T₂ log mean values that are measured. In certain embodiments, the T₂ log mean value range for each type of coke can be predetermined. For example, if the measured T₂ log mean is between 800 ms and 1500 ms, it is indicative of Type C coke.

In another embodiment, the above described “cut-off” method could use a T₁ log mean value instead of the T₂ log mean value.

In another embodiment, a second NMR parameter may be used in addition to a relaxation decay parameter. In certain embodiments, the second NMR parameter may be porosity. The use of T₂ log mean and porosity values allows for “zones” on a plot of porosity versus T₂ log mean to define the classification.

In another embodiment, the T₂ response of known classifications is measured and the sum each T₂ distribution with weightings is used to obtain the measured result on the unknown coke samples. This allows for a percentage of each classification (i.e. 50% Type A, 20% Type C and 30% type D).

In another example, a series petroleum coke samples with masses ranging from approximately 15 to 25 grams were vacuum saturated with 2% w/w KCl in water solution for a minimum of about 2 hours at ambient temperature. The samples were drained of free water and blotted with a paper towel to remove excess moisture. A given sample was loaded into a 40 mm diameter NMR tube and NMR measurements were performed at ambient temperature using an Oxford Instruments Geo Spec 2 NMR spectrometer operating at 2.36 MHz. The NMR measurements consisting of T₂ and T₁-T₂ spectra (bulk measurement) were performed with scan times ranging from 5 minutes to 5 hours depending upon the sample coke morphology and type of NMR measurement. Three types of cokes were tested: sponge, shot, and a dense coke produced from a Heavy Canadian vacuum residue. It was discovered that the log mean T₂ parameter could easily distinguish between the three types of coke morphologies, with sponge coke having a T₂ log mean (LM) of approximately 2500 ms; shot coke T₂ LM of about 320 ms; and dense coke having a T₂ of around 1150 ms. 

What is claimed is:
 1. A method of determining the identity of a petroleum coke sample comprising: obtaining a nuclear magnetic resonance (NMR) measurement of the sample, determining a relaxation decay value of a fluid in the sample from the NMR measurement, comparing the relaxation decay value to relaxation decay values of known petroleum coke materials in a reference group to determine whether the petroleum coke is one of the known materials.
 2. The method of claim 1, wherein the comparing step includes searching a list of known petroleum coke materials and corresponding relaxation decay values.
 3. The method of claim 1, wherein the known petroleum coke materials are selected from the group consisting of sponge-type coke, shot coke, transition coke, dense coke and needle coke.
 4. The method of claim 1, further comprising outputting the result.
 5. The method of claim 1, wherein the result is one of an identification of the substance as a known material in the reference group or determination that the substance is not one of the known materials in the reference group.
 6. The method of claim 1, wherein the relaxation decay value is T₁ relaxation time or T₂.relaxation time.
 7. The method of claim 6, wherein the T₁ relaxation time is the T₁ log mean and the T₂.relaxation time is the T₂ log mean.
 8. The method of claim 1, further comprising determining a porosity value of the sample from the NMR measurement and comparing the porosity value to porosity values of known petroleum coke materials.
 9. The method of claim 8, wherein the known petroleum coke materials are selected from the group consisting of sponge-type coke, shot coke, transition coke, dense coke and needle coke.
 10. The method of claim 1, wherein the sample comprises at least two different known petroleum coke materials and the step of determining a relaxation decay value comprises determining at least two relaxation decay values of a fluid in the sample from the NMR measurement and comparing the relaxation decay values to relaxation decay values of known petroleum coke materials in a reference group to determine whether the petroleum coke sample comprises one or more of the known materials.
 11. The method of claim 10, further comprising determining weightings for the relaxation decay values to determine the percentage of types of known petroleum coke materials in the sample.
 12. The method of claim 1, wherein the fluid is an NMR active fluid.
 13. The method of claim 12, further comprising prior to the step of obtaining the low field nuclear magnetic resonance (NMR) measurement of the sample, saturating the sample with the NMR active fluid.
 14. The method of claim 1, wherein the NMR measurement is a low field NMR measurement.
 15. The method of claim 1, wherein the step of comparing the relaxation decay value includes fitting to a mathematical equation using predetermined T₂ distribution of each COKE type to be classified.
 16. The method of claim 15, wherein the mathematical equation is ERROR=measured T ₂−(Type A T ₂*weight A+Type B T ₂*weight B+ . . . ) 